Push-back racks offer an efficient, high-density storage solution for warehouses looking to optimize space while maintaining easy access to inventory. This racking system is designed for last-in, first-out (LIFO) inventory management, making it an ideal choice for industries with high product turnover.
In this post, we’ll explore how push-back racks work, their benefits and drawbacks, and which products are best suited for this type of storage system.
What Are Push-Back Racking Systems?
Push-back racking systems are a type of high-density storage solution where pallets are stored on inclined rails or carts. As the name suggests, when a new pallet is loaded onto the rack, it pushes the previously stored pallet further back. This design allows for multiple pallets to be stored in the same lane, typically ranging from two to six pallets deep.
How Push-Back Racks Work
Loading Process: Pallets are loaded from the front of the rack onto a cart with wheels that sits on inclined rails. As a new pallet is added, it pushes the previous pallet further back into the storage lane. Each pallet is stored on its own cart, allowing for easy access and movement.
Unloading Process: When a pallet is retrieved, the remaining pallets move forward automatically due to gravity. This keeps the next pallet in line ready for picking without requiring forklifts to enter the rack structure. Push-back racking systems operate on a last-in, first-out (LIFO) principle. This means the most recently stored pallet is the first one retrieved.
Structural Design: Push-back racks can be designed multiple pallets deep, generally between 2 and 5 pallets deep being the most common range. A larger clear space between beam levels is needed to accommodate the pitch of the rails and the height of the carts. Generally these systems are supported by structural frames to store heavier loads.
Benefits of Push-Back Racks
Push-back racks offer a range of benefits for warehouses aiming to improve efficiency and maximize space:
High-Density Storage: Push-back racks allow for deep lane storage, maximizing space usage by reducing the number of aisles needed in a warehouse. This leads to a higher pallet count per square foot, which is especially valuable in space-constrained environments.
Increased Selectivity Compared to Drive-In Racks: Unlike drive-in racks, which require forklifts to enter the rack for pallet retrieval, push-back racks allow for selective access to each lane. Forklifts can pick from the front each time, reducing labor time and improving operational efficiency.
Easy to Operate: Push-back racking systems are designed to be user-friendly. The automatic forward movement of pallets upon retrieval eliminates the need for complex handling, reducing the likelihood of product or rack damage.
Improved Stock Rotation: Although it’s a LIFO system, push-back racks are effective for stock rotation in environments where products with similar turnover rates are stored together.
Ideal for High-Turnover Inventory: Push-back racks are well-suited for warehouses that handle fast-moving products, such as those in the food and beverage or retail industries.
Drawbacks of Push-Back Racks
While push-back racking systems offer high-density storage, they do have some limitations:
LIFO System Limitations: The LIFO system can be a drawback for businesses that need first-in, first-out (FIFO) inventory management. Push-back racks are not ideal for storing perishable goods or products with a strict expiration date.
Higher Initial Cost: Push-back racks tend to be more expensive than traditional selective racking systems due to their complex design, which includes rails and carts for each lane.
Limited Depth: Push-back racks are typically limited to storing a maximum of six pallets deep. For businesses requiring deeper storage lanes, other systems like drive-in racks might be more appropriate.
Less Suitable for Diverse SKUs: Since push-back racks store multiple pallets in the same lane, they are better suited for large quantities of the same product. Warehouses with a wide variety of SKUs might find it harder to organize diverse products within this system.
Ideal Products for Push-Back Racking Systems
Push-back racking systems are designed for high-density storage and fast-moving products. Here are some examples of products that benefit from push-back racks:
Beverages: Push-back racks are ideal for storing beverages, such as soda, bottled water, and alcoholic drinks. These items are often stored in bulk and have a high turnover rate, making them well-suited for LIFO systems.
Packaged Food: Non-perishable packaged foods, such as canned goods or snacks, can be efficiently stored in push-back racks. These products typically move quickly and do not require strict stock rotation, making them a great fit for this racking system.
Consumer Goods: Fast-moving consumer goods (FMCG), such as cleaning products, toiletries, and personal care items, benefit from push-back racking because of the system's ability to handle large quantities of similar items with easy access.
Retail Products: Push-back racks are also ideal for retail warehouses that store products like electronics, apparel, or household goods. These items are often stored in bulk and need quick access for distribution.
Automotive Parts: Warehouses storing tires, engine components, or other automotive parts can benefit from push-back racks, which provide efficient storage and quick retrieval.
Conclusion
Push-back racking systems offer an efficient, high-density storage solution for warehouses that need quick access to fast-moving products. While the LIFO system has its limitations, the benefits of increased storage density, easy accessibility, and improved operational efficiency make push-back racks an excellent choice for industries with high product turnover.
Whether you're managing a beverage distribution center or a retail warehouse, push-back racks could be the perfect solution to streamline your storage and handling processes.
Want to explore how push-back racks can improve your warehouse operations? Contact us today to discuss your storage needs and find the best solution for your business.
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